Intelligent Melt Shop (iMeltshop)
Tenova iMeltShop provides real-time monitoring and dynamic control of the entire steel production process with the aim of maximizing the availability of the plant and improving the overall melt shop performance.
Overview
In steel production, the development of automation and process control systems has grown in parallel with the development of metallurgical technologies applied to individual production stations.
In the classic and widely used architecture of these process control systems, there are solutions designed to obtain the best performance from each of the individual production stations.
The integration between the different production stations is limited to the transmission of process data between a station that has completed the heat in progress and the next station that receives it for subsequent processing.
Even in the presence of a higher control level (Level 3), generally used to transmit production orders to individual production stations, the coordination and management of steel production line is managed by one or more production managers who can, if necessary, can have the support of responsible operating at individual production stations.
This scenario requires a new approach to the process control theme. Hence the request to define a new tool for the process control, designed for the coordination, in real time, of the entire production line, realizing the integration of all work stations.
Tenova iMeltShop is the answer
The purpose of the proposed system is to ensure that the melting responsible has the support in decisions of a tool that allows to automatically drive production flow (from raw material used in charge to continuous casting) and process choices, depending on preset events and rules.
The system also provides a complete collection of information, in real time and at the end of the process, that can be used for analysis and continuous production improvement, product quality and plant maintenance.
The iMeltShop system can, therefore, be defined as a manager of steel plant production process that works by inserting itself between process control of single equipment (Level 2) and higher level systems (MES, ERP, etc.). To this end, improves dynamic control and real time monitoring of the entire steel manufacturing flow, with the aim to maximize the availability of the production line improving the performance.
Technical data
Tenova iMeltShop has been designed using a highly modular structure.
Tenova iMeltShop system consists of fundamental modules (CORE) and optional modules that add functionality and control capabilities to the system.
iMeltShop is therefore a scalable, configurable and expandable system, in order to allow the best adaptation to different production realities and possible future needs.
iSBC: SYSTEM BASIC CONFIGURATOR
This digital twin of the plant replicates all logistics and process dynamics within the plant, from the process time at the furnace, to the casting sequences, to the movement of cranes and cars. Being an offline tool, it can also be used to predict the effect on the operations of the plant upon the implementation of major changes (i.e. relocation or upgrade of equipment, the addition of a LF or of a crane etc.).
iMPS: MANUFACTURING PRODUCTION SENTINEL
This online intelligent module optimizes and coordinates the entire production line in real time. It is the core of iMeltShop. It optimizes the operative procedures and it is able to simulate the best alternative route whenever there is a problem on the standard production route. This intelligent solution is proposed in real time to the operators, taking into account the products in the pipeline (from the ERP) and the actual conditions of the equipment in the plant.
iPPM: PLANT PRODUCTION MONITORING
This module updates the schedule of production flow and performs a predictive estimation of delays using dynamic data analysis. The results are presented as time diagrams (eg Gantt chart) covering the whole process route and as “control cards”, customizable cards that show the key process parameters the customer decides to represent.
iSTS: SHORT TIME SCHEDULING
Support in defining and managing steel meltshop production programs for a period up to 72 hours. It generates the best casting sequence, taking into consideration production targets and possible constraints.
iDMR: DATA MINING & REPORTS
A flexible and fully customizable module that allows the user to create and extract any type or report from recorded data. Reports can be digital or printed. It also allows the monitoring of specific KPIs and can give automatic warnings whenever a certain parameter is out of the specified range. It is a fundamental tool for the continuous improvement of the operations and of the team.
iSCO: SCRAP CHARGE OPTIMIZER
iSCO module performs the scrap charge optimization, in compliance with the general strategy assigned, searching for the minimum value of the overall cost
index defined as the sum of the costs of:
- Cost of the composition of materials in charge, considering the only ones currently available
- Cost of transformation (electrical power, chemical power, slag former, etc.) for the materials considered.
The result of this strategy is to ensure the effective lower cost of the entire melting process.
Innovation
Tenova iMeltShop is a process guide, designed to coordinate the complete production line and to support in its choices who has to manage the production.
The innovative idea of the iMeltShop system is to focus the attention on the type of steel to be produced and, as a result, to harmonize production processes of each individual station involved.
The system stars from the definition of the melting order (quality and quantity) and guides the production to the casting phases of the liquid steel.
The concept of "process route”, that is the integrated control of the entire production process, is the heart of this approach.
iMeltShop controls and regulates all plants involved in the transformation process, to manage them in a coordinated manner and thus achieve maximum efficiency, depending on the assigned strategy.
It improves the consistency and repeatability of the production quality and increases the energy efficiency of the steel plant as a whole.
It allows to improve the estimation and prediction of maintenance, with optimization of time and energy spent for stopping and restarting the plants.
Tenova iMeltShop gives the opportunity to take advantage of different opportunities for the production flexibility of the plant.
The system is an excellent guide for continuous development and performance optimization
Safety
iMELTSHOP: Continuous Training, Service And Real Time Assistance
After commissioning, Tenova is always with their customer through their network of qualified technical specialists around the world or via remote assistance using the innovative Tenova adVISOR technology (a mix of augmented reality and cloud based advanced services such as digital manuals, troubleshooting guidelines etc.). Tenova is proud of the network of enthusiastic customers who have adopted their solutions.
Automation
iMELTSHOP: Design, Installation And Commissioning Of Your iMeltshop Solution
The duration of an iMeltShop implementation depends on the number of modules to implement and typically takes less than six months. The initial phase is focused on collecting all necessary data from the running plant and the current operative specifications. It involves a significant amount of side-by-side time at the running plant with Tenova specialists. Then there is a short period of programming and setting up of the necessary software interfaces with the existing tools. During commissioning, Tenova focuses on the important task of training your employees to utilize the extremely intuitive systems. Only a well-trained crew will be able to give you the maximum out of your new iMeltShop.
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